JP2000153433A - Production control system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To start production even when a stock of a raw material lacks without having an excessive stock by arranging a manufacture indicating part for preparing manufacture indication including a lot number of the raw material used on the basis of a production plan, a blending table and stock quantity. SOLUTION: A manufacture indicating part 4 prepares manufacture indication so as to produce products having the same name by the same manufacturing line as much as possible when preparing its manufacture indication data. Even when stock quantity of a raw material is less than required quantity in producing the products at manufacture indication preparing time, manufacture indication is prepared by adding delivery expected quantity when the required quantity is expected to be delivered up to producing these products by referring to the content of a delivery plan file 1c. The manufacture indicating part 4 informs a weighing indicating part 5 of the manufacture indication prepared here and the content of a recipe data file 1d. The weighing indicating part 5 outputs stock data by receiving these.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production management system for manufacturing toothpastes and the like, and more particularly to a production management system for performing lot management and inventory management of raw materials and products in a manufacturing process.

[0002]

2. Description of the Related Art When products such as toothpastes are produced, it is necessary to perform lot management based on common information management from raw materials to products.

As a system for controlling production and producing a desired quantity of products, for example, the technology described in the following publication is known.

Japanese Patent Application Laid-Open No. 09-50463 discloses that, when a specification change request is issued for a product being manufactured, the actual situation in which the product is sent to the subsequent process with the specifications before the change is automatically grasped. Thus, a technology capable of performing appropriate progress management has been disclosed.

[0005] Japanese Patent Publication No. 05-37789 states that it is possible to correct a production plan when a material or the like capable of increasing the producible quantity is procured while a certain article is being produced. There is disclosed a technology that enables an operator to correct a production plan quantity without delay by giving an instruction to the operator, thereby preventing production stoppage.

[0006] In Japanese Patent Publication No. 05-37788, the determined production execution quantity is set in a plurality of times, and necessary materials and the like according to each set quantity are taken out of the storage facility for each setting. Then, a technique is disclosed in which all the materials and the like are promptly taken out of a storage facility at the start of production by continuously producing articles of a determined production execution quantity.

Further, as a lot number management method, Japanese Patent Application Laid-Open No. 05-342217 discloses that a lot code is converted into a character code which enables comparison of magnitudes between lot symbols to determine whether a product or a semi-finished product is new or old. Discloses a technology that enables efficient first-in / first-out processing.

[0008]

By the way, products produced in batches, such as toothpaste manufacturing processes, in which the production volume of one batch is several tons, include raw materials in which a small amount of raw materials are mixed from a large amount of raw materials. A wide variety of raw materials must be blended.

[0009] However, it is not easy to produce a predetermined quantity of a product according to a production plan without having an excessive stock of raw materials, and to surely manage lots of raw materials and products used for the product. There is a problem.

[0010] The present invention has been made in view of such circumstances, and in the manufacturing process of toothpaste and the like, it is possible to strictly control the raw material and product lots, and furthermore, the raw material without excessive inventory. It is an object of the present invention to provide a production management system capable of starting production even when stocks are insufficient.

[0011]

The invention according to claim 1 is a production management system for managing the production of a product in which a plurality of raw materials are blended, wherein the production management system has a plan for producing the product. A storage unit for storing the described production plan, a mixing table of the raw materials necessary for producing the product, and an inventory amount for each raw material lot, and producing the product based on the production plan and the mixing table A raw material ordering unit for obtaining the required amount of the raw material necessary for the production, further calculating the required amount of the raw material by comparing the required amount with the stock amount, and ordering the raw material in an amount corresponding to the insufficient amount; A production instruction unit for producing a production instruction including a lot number of a raw material to be used based on the production plan, the recipe and the stock amount stored in the production instruction unit; A weighing instruction unit that creates an instruction for the amount of each raw material by lot, and producing the product by blending the weighed raw materials according to the weighing instruction created in the weighing instruction unit. I do.

According to a second aspect of the present invention, the production instruction section associates a lot number of all raw materials used in the product with a lot number of the product for the product produced according to the production instruction. The attached result data is stored in the storage unit.

According to a third aspect of the present invention, the raw material ordering unit stores a delivery plan in which the scheduled delivery date of the ordered raw material is described in the storage unit, and the production instruction unit stores the required raw material Even when the stock is insufficient, a manufacturing instruction to start manufacturing is created in accordance with the expected delivery date.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a production management system according to an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a block diagram showing the configuration of the embodiment. In this figure, reference numeral 1 denotes a storage unit for storing data necessary for production management, and is composed of a production plan file 1a, a raw material inventory data file 1b, a delivery plan file 1c, a recipe data file 1d, and an actual data file 1e. . Reference numeral 2 denotes a production plan creation unit that creates a production plan. Reference numeral 3 denotes a raw material ordering unit for ordering raw materials to a raw material maker based on data stored in the storage unit 1. Reference numeral 3a denotes a delivery date information storage unit in which the number of days that can be delivered by the raw material maker is stored for each raw material. Reference numeral 4 denotes a manufacturing instruction unit that issues a manufacturing instruction based on the data stored in the storage unit 1. Reference numeral 5 denotes a weighing instruction unit for instructing weighing of raw materials. Symbols 6-1 and 6-2 are
A production line control unit that controls the production line. Here, only two production line control units 6-1 and 6-2 are shown, but a production line control unit 6-n may be provided according to the number of production lines.

Next, the operation of the production management system will be described with reference to FIG. First, the production plan creation unit 2 is provided with an input device. The production plan input by the worker using this input device is stored in the production plan file 1a in the storage unit 1.
To memorize. As shown in FIG. 2, the production plan file 1a has a table including “month”, “week”, “product name”, and “production amount”. In production planning,
It is not defined by the date of production, but by how much and how much to produce in the week of the month.

Next, the operation of ordering a raw material from a raw material maker will be described. First, the raw material ordering unit 3 reads the contents of the production plan file 1a and the recipe data file 1d stored in the storage unit 1. As shown in FIG. 3, the recipe data file 1d defines a blending amount of each raw material per unit production amount of a product, and a manufacturing method including a temperature and a stirring time.

Next, the raw material ordering unit 3 calculates the required amount of each raw material and its due date from the production plan and recipe data read from the storage unit 1. Figure 2 shows the calculation of the required amount of each raw material.
Is obtained by multiplying the production amount of a certain product by the unit production amount, and multiplying this value by the blending amount of each raw material shown in FIG. The required amount of each raw material is held in the raw material ordering section 3.

Next, the raw material ordering unit 3 reads the contents of the raw material inventory data file 1b stored in the storage unit 1, compares the previously calculated required amount for each raw material with the inventory amount, and Calculate the shortage for each. As shown in FIG. 4, the raw material inventory data file 1b includes “raw material name”,
A table is provided based on “lot number” and “stock amount”.

Next, the raw material ordering section 3 outputs order data for ordering the shortage amount of each raw material when the shortage occurs or is expected to be short.
In response, the worker places an order with a raw material maker based on the order data. At this time, the raw material ordering unit 3
The delivery date and delivery quantity are determined for each raw material with reference to the delivery date information 3a, which defines the number of days that the raw material maker can deliver for each raw material, and the delivery date and delivery quantity are stored in the storage unit 1. It is stored in the delivery plan file 1c.

The scheduled delivery quantity is the same as the ordered quantity. As shown in FIG. 5, the delivery plan file 1c includes "raw material name", "planned delivery quantity", and "planned delivery date".
Is provided. As the expected delivery date and expected delivery quantity, the worker may input the delivery date and delivery quantity answered by the raw material maker.

Next, when the raw material ordered from the raw material maker is delivered, the operator inputs the delivered amount of the delivered raw material as the receipt data. In response to this, the raw material ordering unit 3 stores the received data in the raw material inventory data file 1b.
Write to

Thus, the raw material inventory data file 1b is updated. At the same time, the raw material inventory data file 1b deletes the data scheduled to be delivered to the corresponding raw material stored in the delivery plan file 1d. Thus, the delivery plan file 1b is updated.

As described above, the ordering of the raw materials is based on the production plan, and only the shortage of the stock amount is ordered. Therefore, it is possible to prevent the stock from being excessive.

Next, the operation of outputting a production instruction will be described. First, the production instruction unit 4 refers to the contents of the production plan file 1a, the recipe data file 1d, the raw material inventory data file, and the delivery plan file 1c stored in the storage unit 1 to determine which product, when, and which On the production line, create production instruction data that specifies how many batches to produce. As shown in FIG. 6, the production instruction data is data in which "production date", "production line", "production batch number", and "use lot" for each raw material to be blended are defined for each "product name". It is.

When producing the production instruction data, the production instruction section 4 produces a production instruction such that the same product name is produced on the same production line as much as possible. Further, even if the stock of raw materials is less than the required amount when producing the product at the time of producing the manufacturing instruction, the required amount of time until the production of this product is determined by referring to the contents of the delivery plan file 1c. Is scheduled to be delivered,
A production instruction is created taking into account the quantity to be delivered. further,
A production instruction is created so that a stock of necessary raw materials is already produced with priority within a production plan.

As described above, when it is known that the necessary stock of raw materials is expected to reach the required amount at the time of producing the product, a production instruction is created in anticipation of the shortage being delivered. Therefore, even if the stock of raw materials is insufficient, production can be started.

Next, an operation for weighing raw materials based on a production instruction will be described. First, the production instruction unit 4 notifies the weighing instruction unit 5 of the production instruction created here and the contents of the recipe data file 1d. In response, the weighing instruction unit 5
Outputs outgoing data for outgoing the raw material defined in the manufacturing instruction.

The operator retrieves raw materials based on the retrieval data. At this time, the retrieval data includes the raw material name and the lot number, and retrieval is performed based on this data.

Next, the weighing instruction section 5 outputs a weighing instruction for each raw material. The weighing instruction output at this time is a raw material name, a lot number, and an amount. Based on this instruction, the raw material is automatically or manually weighed.

As a result, weighing is performed for each raw material and for each lot number. By mixing these raw materials, the lot management of the raw materials at the time of forming the product can be performed reliably.

Next, the operation of mixing the raw materials will be described.
First, the weighing instruction unit 5 is a production line control unit 6-1, 6-2.
Is notified that the weighing of each raw material has been completed.
In response, the production line control units 6-1 and 6-2 request the production instruction unit 4 to send a production instruction. In response to the request for transmission of the manufacturing instruction, the manufacturing instruction unit 4 transmits a manufacturing instruction to the manufacturing line control units 6-1 and 6-2.

Next, the production line controllers 6-1 and 6-2
Receives a manufacturing instruction and manufactures a product based on the manufacturing instruction. At this time, the production line control unit 6-1
6-2 performs production using the raw materials weighed by the weighing instruction unit 5.

Next, when the production is completed, the production line control units 6-1 and 6-2 notify the production instruction unit 4 of the lot numbers of the raw materials used for the produced products. In response to this, the production instruction unit 4 stores the notified lot number as the result data in the result data file 1e in the storage unit 1. FIG. 7 shows an example of the result data. As shown in the figure, the performance data stores a “manufacturing date”, a “product lot”, and each “raw material lot” for each “product name”.

The production instruction unit 4 updates the contents of the raw material inventory data file 1b based on the actual data. This update is performed by subtracting the amount of raw materials used for manufacturing the product from the stock amount stored in the raw material stock data file 1b. With this operation, the lot numbers of the raw materials used can be associated with each product.

For raw material silos and storage tanks for which it is not necessary to perform indirect weighing, the used amounts of raw materials stored in these are stored in the performance data file 1e.

In the manufacture of toothpastes and the like, there is a case where an intermediate product called kneading water is manufactured, the intermediate product is stored, and a few days later, the intermediate product is used to manufacture the product. . In this case, even if there is no stock of raw materials to be mixed later for this intermediate product, the production of the intermediate product can be performed in time with the delivery of the raw materials to be mixed later by referring to the delivery plan. It becomes possible to start. Further, it is possible to preliminarily perform preliminary compounding corresponding to a plurality of lots.

Thus, as in the process of manufacturing toothpaste,
In the production that requires strict lot management and that the production volume of one batch in batch production is several tons or more, and that has the process of using a wide variety of raw materials from large-scale raw materials to small-scale raw materials, , And can produce a specified amount of a specified product on a specified date according to a production plan. Further, for this product, the lot number of the raw material and the lot number of the product can be accurately managed.

The order data output from the raw material ordering section 3 may be output online to a raw material maker to order raw materials. At this time, the delivery file 1c is created based on the scheduled delivery date obtained for the order to the raw material maker.

Further, the retrieval data output from the weighing instruction section 5 may be outputted to the raw material warehouse online to automatically retrieve the retrieval data.

Further, a program for realizing the functions of the processing in FIG. 1 is recorded on a computer-readable recording medium, and the program recorded on this recording medium is read by a computer system and executed, whereby the production management is performed. Processing may be performed. Here, the “computer system” includes an OS and hardware such as peripheral devices. The “computer-readable recording medium” means a portable medium such as a floppy (registered trademark) disk, a magneto-optical disk, a ROM, a CD-ROM, and a storage device such as a hard disk built in a computer system. .

A "computer-readable recording medium" is a program that is dynamically transmitted for a short period of time, such as a communication line for transmitting a program via a network such as the Internet or a communication line such as a telephone line. In this case, a program that holds a program for a certain period of time, such as a volatile memory in a computer system serving as a server or a client in that case, is also included. Further, the above-mentioned program may be for realizing a part of the above-mentioned functions, or may be for realizing the above-mentioned functions in combination with a program already recorded in a computer system.

[0042]

As described above, according to the present invention, since the ordering of the raw materials is performed based on the production plan and the stock amount, the effect of eliminating the excess stock of the raw materials is obtained.

Further, according to the present invention, since lot management is performed even in weighing before manufacturing, an effect is obtained that the lot number of the product and the lot number of the raw material can be accurately correlated.

In addition, since a production instruction is created based on a production plan, and the raw materials are weighed and the product is manufactured in accordance with the production instruction, an effect that the product can be manufactured without error can be obtained. .

[Brief description of the drawings]

FIG. 1 is a block diagram showing a configuration of an embodiment of the present invention.

FIG. 2 is an explanatory diagram illustrating an example of a production plan in the embodiment.

FIG. 3 is an explanatory diagram showing an example of recipe data in the embodiment.

FIG. 4 is an explanatory diagram showing an example of raw material inventory data in the embodiment.

FIG. 5 is an explanatory diagram showing an example of a delivery plan in the embodiment.

FIG. 6 is an explanatory diagram showing an example of a manufacturing instruction in the embodiment.

FIG. 7 is an explanatory diagram showing an example of performance data in the embodiment.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Storage part, 2 ... Production plan preparation part, 3 ... Raw material ordering part, 3a ... Delivery date information storage part, 4 ... Manufacturing instruction part, 5 ... Weighing instruction part, 6 -1, 6-2: Production line control unit.

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Shigeru Yasuda 1-3-7 Honjo, Sumida-ku, Tokyo F-term in Lion Corporation (reference) 3C042 RJ07 RJ10 RJ11 RL17 5B049 BB07 CC21 CC27 EE02

Claims (3)

[Claims] 1. A production management system for managing the production of a product containing a plurality of raw materials, wherein the production management system includes: a production plan in which a plan for producing the product is described; A storage unit for storing a necessary mixing table of the raw materials and an inventory amount for each raw material lot; and obtaining a necessary amount of the raw materials necessary for producing the product based on the production plan and the mixing table. The required amount and the stock amount are compared to determine the shortage amount for each raw material,
A raw material ordering unit for ordering raw materials in an amount corresponding to the shortage amount; and a manufacturing method for creating a manufacturing instruction including a lot number of the raw materials used based on the production plan, the recipe and the stock amount stored in the storage unit. An instruction unit, and a weighing instruction unit that creates an instruction for the amount of each raw material according to the production instruction created in the production instruction unit. The weighing unit weighs according to the weighing instruction created in the weighing instruction unit. A production management system, wherein the product is produced by blending selected raw materials. 2. The manufacturing instruction section stores, in a product manufactured according to the manufacturing instruction, results data in which lot numbers of all raw materials used for the product are associated with lot numbers of the product. The production management system according to claim 1, wherein the information is stored in a unit. 3. The raw material ordering unit stores, in the storage unit, a delivery plan in which a scheduled delivery date of the ordered raw material is described, and the production instruction unit is configured to execute a process when the stock of necessary raw materials is insufficient. 2. The production management system according to claim 1, wherein a production instruction for starting production is created in accordance with the expected delivery date.